Processes for forming epoxy resin compositions and separation processes

A process for making a liquid epoxy resin composition, the process comprising:

• reacting a mixture comprising an alcohol of biological origin, an epihalohydrin, and a catalyst to form a first composition comprising a halohydrin reaction product;
• introducing an alkaline reagent with the first composition to form a second composition comprising a glycidated product, residual halohydrin reaction product, and a salt;
• introducing a liquid epoxy resin with the second composition to form a liquid resin mixture;
• removing unreacted epihalohydrin from the liquid resin mixture;
• separating the salt from the liquid resin mixture;
• and
• after the separating the salt from the liquid resin mixture, forming the liquid epoxy resin composition by:
• converting at least a portion of the residual halohydrin reaction product in the liquid resin mixture to an epoxy resin;
• performing a liquid-liquid separation of the liquid resin mixture;
• or
• combinations thereof.

A process for converting a substrate to a liquid epoxy resin composition, the process comprising:

• reacting a mixture comprising the substrate, an epihalohydrin, and a catalyst to form a first composition comprising a halohydrin reaction product and a salt, the substrate comprising an alcohol of biological origin, an alcohol present in a resin waste stream, an alcohol present in a resin recycle stream, or combinations thereof;
• introducing an alkaline reagent with the first composition to form a second composition comprising a glycidated product, residual halohydrin reaction product, and a salt;
• introducing a liquid epoxy resin with the second composition to form a liquid resin mixture, the liquid epoxy resin having a viscosity that is about 15 Pa·s or less at 25° C.;
• removing unreacted epihalohydrin from the liquid resin mixture;
• and
• separating the salt from the liquid resin mixture to form the liquid epoxy resin composition.

A process for forming an epoxy resin composition, the process comprising:

• reacting a mixture comprising a substrate comprising at least one hydroxyl group, an epihalohydrin, and a catalyst to form a first composition comprising a halohydrin reaction product;
• introducing an alkaline reagent with the first composition to form a second composition comprising an epoxy resin product, a residual halohydrin reaction product, and a salt;
• introducing a liquid epoxy resin with the second composition to form a liquid resin mixture, the liquid epoxy resin having a viscosity that is about 15 Pa·s or less at 25° C.;
• and
• removing unreacted epihalohydrin from the liquid resin mixture to form the epoxy resin composition.